Composite Applications
Large-format AM speeds plug production for manufacture of composite boat molds
Hungarian manufacturer Rapid Prototyping transitioned its conventional foam milling process to 3D printing to produce faster, higher quality, recyclable foam plugs and composite boat molds.
Hannah Mason
Technical Editor, CompositesWorld
Carbon fiber satellite arm reduces weight, simplifies assembly onto naval vessels
Satcom developer EM Solutions partnered with ACS Australia to replace an aluminum arm design with a 65% lighter, one-piece, corrosion-resistant carbon fiber/epoxy alternative.
Read MoreOptimized rib-reinforced hollow composites via printed molds
Addyx topology optimization and water-soluble mandrel enables simultaneous rib and skin layup for one-shot, high-strength, lightweight structures.
Read MorePull-wound carbon fiber poles enable lightweight, compact, rigid emergency stretcher
Based on military feedback, Epsilon Composite developed an optimized, foldable stretcher that combines telescopic pull-wound carbon fiber tubes.
Read MoreComposite wrap system combats corrosion in industrial tank repair
A fiberglass and carbon fiber composite wrap system enabled an Australian nickel mine to quickly repair a stainless steel ammonium sulphate feed tank and protect against future corrosion.
Read MoreDesigning an infused, two-piece composite baseball bat
With its Icon BBCOR bat, Rawlings leveraged its experience in braided fabrics and RTM to create an optimized, higher-performance two-piece design.
Read MoreDesigning and manufacturing turbine test nacelles
Michigan-based Ground Test Solutions (GTS) shares the design and manufacturing processes involved in building composite nacelle components used in testing jet and helicopter engines.
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Optimized CFRP gantry beam enhances Ultimate cutting machines
CompoTech, Kongsberg PCS collaboration integrates foam-cored design, automated placement of pitch and PAN fibers to achieve award-winning increase in speed and precision.
Ginger Gardiner
Senior Technical Editor, CompositesWorld
Repurposing wind blades as functional community art pieces
Ohio-based Canvus Inc. upcycles fiberglass wind blades, car tires and post-consumer plastics to create outdoor furniture that amplifies sustainability messages in community spaces.
Read MoreMulti-material, self-sensing, 3D-printed scoliosis braces
Startup Fited and Brightlands Materials Center have developed a lighter weight, thinner CFRP corrective brace, including pressure sensors made from continuous carbon fibers.
Read MoreMold 3D printing helps automate composite bathtub, shower production
As part of its efforts to automate as much of its production process as it can, Lyons Industries acquired a Massivit 10000 additive manufacturing system to quickly produce high-performance molds and support fixtures.
Read MorePull-wound fiberglass composite 5G utility poles enable easier, faster installation
EasyStreet Systems is working with Exel Composites to develop and certify pull-wound fiberglass utility poles aimed at durable, lightweight poles for 5G small cell systems.
Read MoreUrban furniture project demonstrates green potential for composite 3D printing and recycled materials
Large-format AM specialist Caracol and partners designed custom, 3D-printed outdoor furniture with glass fiber-reinforced recycled polypropylene, and conducted an LCA to evaluate and improve the process.
Read MoreBio-based epoxy, recycled materials increase sustainability of all-terrain snowboards
Aiming for a smaller environmental footprint while maintaining high performance, Salomon’s Highpath snowboard line incorporates bio-based epoxy, glass and basalt fiber stringers and recycled materials.
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Composite materials, design enable challenging Corvette exterior components
General Motors and partners Premix-Hadlock and Albar cite creative engineering and a move toward pigmented sheet molding compound (SMC) to produce cosmetic components that met strict thermal requirements.
Hannah Mason
Technical Editor, CompositesWorld
Recycling hydrogen tanks to produce automotive structural components
Voith Composites and partners develop recycling solutions for hydrogen storage tanks and manufacturing methods to produce automotive parts from the recycled materials.
Read MoreNanomaterials optimize performance of space-ready carbon fiber composite panels
A recent ESA project led by Adamant Composites aimed to mature nanomaterial-enhanced CFRP for lighter weight, more thermally and electrically conductive materials for manufacturing satellite structures.
Read MoreRunning shoe insoles get a lift with thermoplastic fiberglass tapes
FlexSpring insoles take advantage of unidirectional, continuous fiberglass and thermoplastics to enable next-level performance for the everyday runner.
Read MoreLighter, stronger, faster bionic hand aided by composites design
Psyonic’s touch-sensing prosthetic hand leverages bionic technology, 3D printing and a carbon fiber composite exterior for light weight, high strength and high-tech functionality.
Read MoreRefurbished Einstein yacht demonstrates innovative composites repair and redesign
Years of creative engineering work went into resurrecting the composites-intensive IMOCA 60 racing yacht — with award-winning results.
Read MoreHigh-temperature composite 3D printing facilitates design, manufacture of deployable space structures
Opterus R&D employs an AON3D printer and OOA prepregs to build the tooling, prototypes and end-use versions of its foldable CFRP satellite structures.
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CFRP planing head: 50% less mass, 1.5 times faster rotation
Novel, modular design minimizes weight for high-precision cutting tools with faster production speeds.
Ginger Gardiner
Senior Technical Editor, CompositesWorld
CFRP telescopic mast technology adds height, performance to mobile police surveillance
CompoTech’s Compolift technology leverages automated filament winding to provide high-strength, high-stiffness extendable masts for use on mobile surveillance vehicles, boats and more.
Read MoreCFRP tubes enable lightweight advanced fuel sensing gauges
Liquid Measurement Systems’ carbon fiber composite-based capacitance probes provide durable, corrosion-resistant fuel gauging for a variety of aircraft, including a newly launched onboard processing probe (OPP).
Read MoreKite-based energy system aims for high-output, low-impact wind energy
Netherlands-based startup Kitepower’s Falcon airborne wind energy (AWE) system deploys a fiberglass-intensive kite to generate wind energy with a low ground footprint.
Read MorePrefabricated composite panels, joining system ease catamaran construction
New Zealand-based G&T Marine reduces assembly and construction time with ATL Composites’ composite DuFLEX panels.
Read MoreCarbon fiber composite hydrofoils to enable “world’s fastest” electric ferry
The Candela P-12 Shuttle, set to launch in Stockholm, Sweden, in 2023, will incorporate lightweight composites and automated manufacturing to combine speed, passenger comfort and energy efficiency.
Read MoreVestas implements composites 3D printing to increase efficiency for blade alignment tools
A Markforged digital repository and multi-material 3D printers enable faster, more accurate and less costly manufacture of a variety of tools and blade components across Vestas sites.
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